Thermal Interface Material Application Using Custom Die

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Solution Overview

Problem

Conventional phase change material (PCM) application processes are costly, difficult to apply correctly, limited in part configuration and size, and challenging to keep clean, with issues in liner release and shipping without distortion.

Innovation Solution

A system and method for applying thermal interface materials (TIMs) using a die that is customized in shape and size, pressed through a liner with pressure, dwell, heating, and cooling, allowing for tamping and cutting of TIMs without puncturing the liner, enabling application to various substrates and components with reduced waste and improved handling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional phase change material application processes are used, then thermal interface materials can be applied to components, but the process is costly and difficult to apply correctly

Engineering Contradiction:

Improveease of applicationVSAvoidapplication efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The thermal interface material is pre-applied to a liner before component assembly. The liner serves as a carrier that allows the TIM to be prepared in advance, eliminating the need for complex on-site application processes and enabling simpler, more reliable application.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A liner is introduced as an intermediary carrier between the TIM and the component. The liner simplifies handling and application by providing a stable base for the TIM, making the application process easier and more consistent while maintaining productivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If conventional PCM application processes are used, then TIM can be applied, but part configuration and size are limited

Engineering Contradiction:

Improvepart configuration flexibilityVSAvoidapplication accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The TIM is applied in specific locations and configurations directly on the liner where needed. This allows customization of TIM placement for different component geometries and heat transfer requirements, improving adaptability while maintaining precise application through controlled dispensing or placement on the liner.

Inventive Principle:

Principle #3Local quality

3Object-affected harmful factors

If conventional PCM application processes are used, then TIM can be applied, but maintaining cleanliness is challenging

Engineering Contradiction:

ImprovecontaminationVSAvoidprocess simplicity

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The liner acts as a protective intermediary that contains the TIM during handling and application. This prevents contamination of the TIM and surrounding areas, making cleanliness maintenance easier while keeping the process simple and straightforward.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If conventional PCM application processes are used, then TIM can be applied, but liner release and shipping without distortion is difficult

Engineering Contradiction:

Improveapplication reliabilityVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The TIM is pre-applied to the liner in a controlled manner before component assembly. This preliminary positioning ensures correct placement and reduces the risk of distortion during subsequent handling and shipping, improving application reliability without adding significant process complexity.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables efficient, cost-effective, and distortion-free application of TIMs to a wide range of components, reducing waste and simplifying the process while maintaining high thermal conductivity, addressing the limitations of conventional PCM application methods.

Implementation Method 1

pressed through a liner with pressure, dwell, heating, and cooling

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

maintaining high thermal conductivity

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

pressed through a liner with pressure, dwell, heating, and cooling

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 4

pressed through a liner with pressure, dwell, heating, and cooling

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS11014203B2System for applying interface materials

Publication Date: 2021.05.25 LAIRD TECHNOLOGIES INC

AI summary

A system for applying thermal interface materials to components includes a supply of thermal interface material and a die. The die is operable for pushing against and/or removing a portion of the thermal interface material that is between the die and a corresponding one of the components. The portion of the thermal interface material is removed from the supply and applied to the corresponding one of the components.